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I have had no luck finding a local supplier of 9x12 chipboard.... I'd just rather try to find somewhere I can pick up and not have to pay shipping... and if possible, less than 825 sheets on the first order!

Hnnmm okay, so I got them now, but the problem is they don't fit in my 9x12 mailers... they are just a TAD too big/the mailer is a TAD too small.... any suggestions? I could always go to a 10x13 or something, but then if the paper were to shift opposite the protector, then it is "exposed" and could easily bend... And taping is "dangerous" because it could rip the paper when removed.

You could try using a 10x13 protector and have a piece of paper that fits exactly, then you cut four "courners" in that paper around where the courners of the 9x12 is. Then finally you "flip" the corners of the 9x12 into the holes in the 10x13.

It requires some work, but it should work without damaging the 9x12 mailer and might be worth a shot if you cant find a 9x12 cardboard protecter that fits your 9x12.

I am sorry for my english, Ill try to explain it again but to make it easier for you to understand Ive created an image showing how it works.

If you take a look on the image attached. What it displays is two papers, the one in white is the "position" protection and is a whole paper at that size.
The light blue paper, is the image/photo that should be protected.

What you do is cut four courners slightly bigger than where the "image/photo" corners is on the white protection paper. Then you flip those corners up and put the "image/photo" so its corners will be covered by the protection paper corners.

Then the "image/photo" will stay placed there during the sending, and it will be easily detached when arrived to the customer without damaging anything.

This is how I received one of those "limited printed editions" of a painting, and it seemed to work great. Though I guess it will make the shipping expence slightly bigger due to the bigger protective envelope and the protection paper.

If then everything you need is a template in a thicker cardboard, who has the corners cut out at the exact points you need it. Then place the cardboard on top of a few others and align them, finally cut the holes with a sharp knife. That way you would be able to cut at least 10 "protection sheets" at once.

Anyway I hope you will manage to find a solution that will fit your needs

And be sure to update the thread if you find something that could help others as well.